PERMIT MEMORANDUM 98-174-TV DRAFT 5
OKLAHOMA DEPARTMENT OF ENVIRONMENTAL QUALITY
AIR QUALITY DIVISION
MEMORANDUM July 3, 2006
TO: Dawson Lasseter, P.E., Chief Engineer, Air Quality Division
THROUGH: Herb Neumann, P.E., Tulsa Regional Office
THROUGH: Grover Campbell. P.E., Existing Source Permits Section
THROUGH: Peer Review
FROM: David Schutz, P.E., New Source Permits Section
SUBJECT: Evaluation of Operating Permit Application Number 98-174-TV
Lafarge Building Materials Inc. (Lafarge)
Portland Cement Manufacturing Facility
Section 22 – T20N – R14E, Rogers County
Directions: I-44 to 129th East Ave, North 2 miles to Apache.
East 1 mile to 145th East Ave, North to entrance.
SECTION I. INTRODUCTION
This facility operates as a Portland cement manufacturing plant (SIC 3241). It was originally constructed / operated as Dewey Portland Cement Company in the early 1960s. Dewey merged with American Marietta and the facility was re-named Martin Marietta Cement. In 1983 Blue Circle Cement acquired and operated this facility until 2002 when it was sold to Lafarge. The applicant submitted a timely Title V operating permit application on June 26, 1998, for this major source.
SECTION II. PROCESS DESCRIPTION
The facility produces Portland and masonry cements, and other cement products using the dry process. The raw materials include limestone (oxides of calcium), aluminum, iron and silica, which are first ground to a powder. Next they are calcined at temperatures of around 2,600oF in a rotary cement kiln to produce “clinker.” The clinker is then finely ground and mixed with approximately 5% gypsum to produce cement. At maximum capacity, a feed rate of approximately 4,070 tons per day of raw materials may be fed to two kilns to produce a maximum total (both kilns) of 96 TPH of clinker. Approximately 43% by weight of the raw materials are lost in the calcining process. Each rotary kiln is 425 feet long and 12 to 14 feet in diameter. Originally fired by natural gas, the facility was converted to coal commencing in 1974.
The Finish Mill system is a rotating ball mill used to grind the clinker, gypsum, and fly ash into the final cement product. The three finish mills have a design capacity to produce 141 TPH of cement.
The Clinker Cooler System consists of the #1 and #2 Clinker Coolers, which have been modified in order to increase their heat transfer efficiency and which were involved in netting for Permit No. 95-290-O. The purpose of the clinker cooler is to cool the hot clinker from the kiln so that it may be handled by the transport system and to recoup heat from the clinker in order to utilize less fuel in the kiln process.
The final step in the process is storing, handling, and packaging to ship the final products by truck and rail. Particulate emissions from each step of these processes (as well as the grinding, calcining and cooling) are controlled by air systems with fabric filters. In many cases the fabric filters have a primary purpose of product recovery or separation.
SECTION III. EQUIPMENT
Grandfathered
EUG 1 Raw Material Crushing and Transfer
EU ID# / Point ID# / EU Name/Function / Installation Date101 / EP01 / Primary/secondary crushing system / 1961
102 / EP02 / Junction house / 1961
EUG 2A Raw Mills and Auxiliary Equipment
EU ID# / Point ID# / EU Name/Function / Installation Date
211 / EP03 / #1 Discharge chute, separator, bucket elev. / 1961
221 / EP04 / #2 Discharge chute, separator, bucket elev. / 1964
EUG 2B Raw Mills Auxiliary Equipment
EU ID# / Point ID# / EU Name/Function / Installation Date
212 / EP06 / Raw mill FK pump hoppers / 1961
213 / EP06 / Raw mill #1 weigh meters and feed belts system / 1961
222 / EP05 / Raw mill M pump hopper / 1964
223 / EP05 / Raw mill #2 weigh meters and feed belts / 1964
EUG 3 Raw Blending and Raw Silos
EU ID# / Point ID# / EU Name/Function / Installation Date
301 / EP07 / Blend silos #1 and #2 / 1961
302 / EP10 / Raw silo #3 / 1961
303 / EP11 / Raw silo #4 / 1961
304 / EP11 / Raw silo #6 / 1961
EUG 4A Kiln Feed Pumps
EU ID# / Point ID# / EU Name/Function / Installation Date
401 / EP08 / Kiln feed pumps #1,2,3 / 1961
EUG 4C Kiln Feed Systems
EU ID# / Point ID# / EU Name/Function / Installation Date
403 / EP12 / Kiln #1 feed system / 1961
404 / EP13 / Kiln #2 feed system / 1964
EUG 6B Clinker Handling
EU ID# / Point ID# / EU Name/Function / Installation Date
603 / EP18 / #3 Hot belt / 1961
604 / EP19 / #4 Hot belt / 1961
605 / EP20 / Transfer to clinker storage (clinker belts) / 1961
606 / EP57 / Clinker elevators / 1961
EUG 7A Finish Mill #1 System
EU ID# / Point ID# / EU Name/Function / Installation Date
703 / EP21 / #1 Bucket elevator and separator / 1961
702 / EP22 / Finish mill #1 / 1961
EUG 7B Finish Mill #2 System
EU ID# / Point ID# / EU Name/Function / Installation Date
706 / EP24 / #2 Bucket elevator and separator / 1964
705 / EP26 / Finish mill #2 / 1964
EUG 7D Finish Mills #1 and #2 Feed Belts
EU ID# / Point ID# / EU Name/Function / Installation Date
701 / EP23 / Finish mill #1 feed belt / 1961
704 / EP25 / Finish mill #2 feed belt / 1964
EUG 8 Rail Loading
EU ID# / Point ID# / EU Name/Function / Installation Date
811 / EP48 / Silo 8 rail loading spout / 1961
812 / EP47 / Silo 10 rail loading spout / 1961
813 / EP46 / Silo 12 rail loading spout / 1961
814 / EP45 / Silo 14 rail loading spout / 1961
815 / EP44 / Silo 18 rail loading spout / 1961
EUG 9 Truck Loading
EU ID# / Point ID# / EU Name/Function / Installation Date
901 / EP41 / West truck loading spout / 1961
902 / EP40 / West truck loading spout / 1961
EUG 10 Packhouse
EU ID# / Point ID# / EU Name/Function / Installation Date
1001 / EP29 / Packing system #1 / 1961
1002 / EP30 / Packing system #2/2A / 1961
1003 / EP32 / Packing system #3 / 1961
1004 / EP33 / Packing system #4 / 1961
1005 / EP31 / Packhouse bag cleaner / 1961
EUG 12A Dust Handling
EU ID# / Point ID# / EU Name/Function / Installation Date
1202 / EP42 / Dust unloading / 1961
1203 / EP10 / Silo #5 / 1961
EUG 13A Rail Cement Storage Silos
EU ID# / Point ID# / EU Name/Function / Installation Date
1301 / EP34 / Rail silo 7 (masonry) / 1961
1302 / EP35, 54 / Rail silo 8 / 1961
1304 / EP35, 54 / Rail silo 10 and interstice C* / 1961
1306 / EP35, 54 / Rail silo 12 / 1961
1308 / EP35, 54 / Rail silo14 and interstice E* / 1961
1310 / EP35 / Rail silo 16 / 1961
1303 / EP35 / Rail silo 9 / 1961
1305 / EP35 / Rail silo 11 and interstice D* / 1961
1307 / EP35 / Rail silo 13 and interstice E* / 1961
1309 / EP35 / Rail silo 15 / 1961
* An interstice is a storage space constructed between two adjacent silos. This creates additional storage space by using existing structures with minimal extra wall material.
EUG 13B Truck Cement Storage SilosEU ID# / Point ID# / EU Name/Function / Installation Date
1311 / EP37, 39 / Truck silo interstice A / 1961
1313 / EP37, 39 / Truck silo 1 / 1961
1315 / EP37, 39 / Truck silo 3 / 1961
1317 / EP37, 39 / Truck silo 5 / 1961
1318 / EP37, 39 / Truck silo5A / 1961
1312 / EP38 / Truck silo interstice B / 1961
1314 / EP38 / Truck silo 2 / 1961
1316 / EP38 / Truck silo 4 / 1961
1319 / EP38 / Truck silo 6 / 1961
1320 / EP38 / Truck silo 6A / 1961
EUG 14 Plant Fugitive Sources
EU ID# / Point ID# / EU Name/Function / Installation Date
1401 / NP01 / Unpaved roads / 1961
1402 / NP02 / Stockpiles, crane storage / 1961
1403 / NP03 / Paved roads / 1961
1404 / NP04 / Heavy equipment travel / 1961
1405 / NP05 / Quarry operations / 1961
1408 / NP08 / Kiln #1 dust bin / 1961
1409 / NP09 / Kiln #2 dust bin / 1961
Note: The process rate of each unit is shown in the Emission Section.
Permitted
EUG 3A Raw Blending and Raw Silos
EU ID# / Point ID# / EU Name/Function / Installation Date1203 / EP-61 / Clinker additives silo / 2005
1204 / EP-62 / Clinker additives silo / 2005
EUG 4B Kiln Feed X-Pump
EU ID# / Point ID# / EU Name/Function / Installation Date
402 / EP09 / Kiln feed x-pump / 1987
EUG 5A Kiln #1 System
EU ID# / Point ID# / EU Name/Function / Installation Date
501 / EP14 / Kiln, screw conveyor, & bucket elevator / 1964
EUG 5B Kiln #2 System
EU ID# / Point ID# / EU Name/Function / Installation Date
502 / EP15 / Kiln, screw conveyor, & bucket elevator / 1964
EUG 6A Clinker Coolers
EU ID# / Point ID# / EU Name/Function / Installation Date
601 / EP16 / Clinker cooler #1 / 1961 / 1995
602 / EP17 / Clinker cooler #2 / 1964 / 1997
EUG 6C Plant Fugitive Sources
EU ID# / Point ID# / EU Name/Function /
Installation Date
63 / EP63 / Feed hopper / 200564 / EP64 / Clinker stockpile conveyor / 2005
EUG 7C Finish Mill #3 System
EU ID# / Point ID# / EU Name/Function / Installation Date
707 / EP52 / Finish mill #3 clinker/gypsum transfer belt / 1997
708 / EP50 / Finish mill #3 / 1997
709 / EP51 / Finish mill #3 bucket elevator / 1997
711 / EP51 / Finish mill #3 cement conveyor / 1997
710 / EP49 / Finish mill #3 separator / 1997
712 / EP53 / Finish mill #3 six-ton bin / 1997
EUG 9A Truck Loading
EU ID# / Point ID# / EU Name/Function / Installation Date
65 / EP65 / NewCem Conveyor No. 1 / 2005
79 / EP79 / NewCem Conveyor No. 2 / 2005
EUG 11 Coal/Coke Handling
EU ID# / Point ID# / EU Name/Function / Installation Date
1101 / EP27 / Coal/coke unloading / 1974
1102 / EP28 / Coal/coke drag conveyor, bucket elevators / 1974
1103 / EP28 / Coal/coke crusher / 1974
1104 / EP55 / Coal silo #1 / 1997
1105 / EP56 / Coal silo #2 / 1997
EUG 12B Dust Handling
EU ID# / Point ID# / EU Name/Function / Installation Date
1201 / EP43 / T-10 Dust silo / 1994
1202 / EP60 / Flyash silo / 2004
EUG 15: Miscellaneous Sources
EU ID# / Point ID# / EU Name/Function /
Installation Date
66 / EP-66 / 66.4-hp Diesel engine / 200580 / EP-80 / 66.4-hp Diesel engine / 2005
SECTION IV. EMISSIONS
Estimates for potential emissions of the facility sources are based the following factors and data:
Point ID / Process Description / Process Rates / Emission Factor / Factor ReferenceEP01 / Primary/secondary crushing system / 800 TPH, 14,400 ACFM / 0.025 gr/acf / Baghouse mfg
EP02 / Junction house / 800 TPH,
2,600 ACFM / 0.025 gr/acf / Baghouse mfg
EP03 / Raw Mill #1 discharge chute, separator, bucket elev. / 1.2 MMBTUH,
100 TPH
36,000 ACFM / NOx: 0.1 lb/MMBTU / AP-42 (7/98) Section 1.4
CO: 0.084 lb/MMBTU / AP-42 (7/98) Section 1.4
VOC: 0.0055 lb/MMBTU / AP-42 (7/98) Section 1.4
SO2: 0.0006 lb/MMBTU / AP-42 (7/98) Section 1.4
PM: 0.025 gr/acf / Baghouse mfg
EP04 / Raw Mill #2 discharge chute, separator, bucket elev. / 1.2 MMBTUH,
100 TPH
36,000 ACFM / NOx: 0.1 lb/MMBTU / AP-42 (7/98) Section 1.4
CO: 0.084 lb/MMBTU / AP-42 (7/98) Section 1.4
VOC: 0.0055 lb/MMBTU / AP-42 (7/98) Section 1.4
SO2: 0.0006 lb/MMBTU / AP-42 (7/98) Section 1.4
PM: 0.025 gr/acf / Baghouse mfg
EP05 / Raw mill M pump hopper, weigh meter & feed belts / 100 TPH,
4,000 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP06 / Raw mill FK pump hoppers, weigh meters & feed belts / 100 TPH,
4,000 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP07 / Blend silos #1 and #2 / 200 TPH, 14,400 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP08 / Kiln feed pumps #1,2,3 / 500 TPH,
1,340 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP09 / Kiln feed x-pump / 200 TPH,
1,000 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP10 / Raw silo #3 and #5 / 200 TPH,
7,800 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP11 / Raw silo #4 and #6 / 200 TPH,
5,000 ACFM / PM: 0.025 gr/acf / Baghouse mfg
Point ID / Process Description / Process Rates / Emission Factor / Factor Reference
EP12 / Kiln #1 feed system / 120 TPH,
5,200 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP13 / Kiln #2 feed system / 120 TPH,
5,200 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP14 / Kiln #1, screw conveyor, & bucket elevator / 48 TPH clinker
160,000 ACFM
172 MMBTUH / NOx: 6.0 lb/ton clinker / AP-42 (1/95) Section 11.6
CO: 33.22 lb/hr / Stack tests May 1994
VOC: 0.028 lb/ton clinker / AP-42 (1/95) Section 11.6
SO2: 10 lb/ton clinker / AP-42 (1/95) Section 11.6
PM: 0.025 gr/acf / Baghouse mfg
EP15 / Kiln #2, screw conveyor, & bucket elevator / 48 TPH clinker
160,000 ACFM
172 MMBTUH / NOx: 6.0 lb/ton clinker / AP-42 (1/95) Section 11.6
CO: 41.32 lb/hr / Stack tests May 1994
VOC: 0.028 lb/ton clinker / AP-42 (1/95) Section 11.6
SO2: 10 lb/ton clinker / AP-42 (1/95) Section 11.6
PM: 0.025 gr/acf / Baghouse mfg
EP16 / Clinker cooler #1 / 48 TPH,
43,000 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP17 / Clinker cooler #2 / 48 TPH,
43,000 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP18 / #3 hot belt / 48 TPH,
1,000 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP19 / #4 hot belt / 48 TPH,
1,000 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP20 / Transfer to clinker storage (clinker belts) / 96 TPH,
2,600 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP21 / Finish mill #1 bucket elevator and separator / 50 TPH
31,750 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP22 / Finish mill #1 / 50 TPH
4,000 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP23 / Finish mill #1 feed belt / 50 TPH
4,000 ACFM / PM: 0.025 gr/acf / Baghouse mfg
EP24 / Finish mill #2 bucket elevator and separator / 50 TPH